Multi-use fill height test devices

ABSTRACT

A novel device and related methods which provide manually adjustable standards and controls for quality inspection systems for filling and sealing equipment. The device provides an adjustable product height simulator which is used to calibrate and quality assurance test the performance of quality inspection systems on a filling and sealing line. The height simulation level is detectable without changing sensitivity of the quality inspection system&#39;s product level sensor. The device is readjustable for a plurality of uses, rugged for repeated multiple use, and does not degrade over time. Base and top (capping) characteristics provide further adjustable simulation comprising entrapped gas phase between the product and container cap, missing caps, and simulated container forms.

CONTINUITY

This application is a continuation of our co-pending U.S. patentapplication Ser. No. 643,864, filed Jan. 22, 1991, which is acontinuation of U.S. patent application Ser. No. 505,960, filed Apr. 6,1990, now U.S. Pat. No. 5,010,760.

FIELD OF INVENTION

This invention relates to container filling and sealing equipment andmore particularly to fill level calibration and control devices, andrelated methods, for quality control and inspection systems forcontainer filling and sealing equipment.

PRIOR ART

In the containerized beverage and containerized food arts, an automatedfilling and sealing production line is often used for multiple containershapes and sizes and must accurately and repeatably fill each containerwith a particular product to levels and volumes which are individuallyand independently set for each product and container. In addition tosetting the mechanical control parameters of the filling and sealingequipment to establish each specific fill level and volume, similar testor inspection parameters must be set for an associated qualityinspection system. In order to reduce the costs related to setting andresetting each line and performing periodic inspection to assurequality, it is desirable to provide easily accessible stored referencestandards and controls for the quality inspection system for line orrun. As an example, it is common practice in the industry to requirefill liquid fill volume accuracy to be within one-tenth of an ounce.Each time a line is newly set-up and periodically within each run, testsmust be conducted to assure the established tight tolerance requirementsare met.

In the past, it has been a practice to set fill levels using prefilledbottles, cans, or containers identical to those actually being used on afilling and sealing line to initially set and then periodically test thecorresponding performance of the fill height quality inspection system.In this practice, one container is filled to a product level whichrepresents the maximum underfill reject level. Another container isfilled to a level which exceeds the maximum underfill reject level by anadditional fill amount representing the minimum detection resolution ofthe quality inspection system for that container configuration.Procedurally, these containers have been the standards and controls usedto calibrate the quality inspection system for fill level detection bywhich the fill level for a line for new containers has been establishedand by which fill level performance test has been periodically checkedas part of a quality assurance test program run during filling andsealing.

A number of problems have been encountered through the use of theaforestated prior art practice which include difficulties in adjustingquality control equipment due to product sloshing, loss of accuratevolumetric/height presentation due to denting and other malformation ofthe containers through use, breakage of expensive prototype containersduring line set-up, and variations in fill height and other relatedmeasurement parameters due to aging during storage between runs.

A product which represents an early attempt to solve these and otherproblems was earlier provided by the assignee of the present invention,Servi-Tech, Inc. of Salt Lake City, Utah, in the form of a dimensionallystatic fill height test can. For each fill configuration, the staticServi-Tech, Inc. test can comprises three fixed height solid plasticsimulated containers or cans which simulate three fluid levels, NO/GO(reject every time), GO/NO-GO (reject approximately half the time), andGO (pass every time). The simulated cans are made of high impactinjection molded plastic, machined in calibrated increments to acustomer's filling and sealing line requirements. Once machined, acalibrated top lid is statically permanently secured as the top of thesimulated can, using an adhesive or the like, and engraved with thespecific fill height to make a permanent static unit. Designed to meetrequirements of liquid canning, thousands of these simulated cans havebeen sold. Using this type of fill height test system eliminates anyfurther need for creation of replacement liquid filled test cans orsimulations thereof. The simulated cans comprise the followingadditional features: (1) a hollow region below the top lid to simulategas space above the liquid in a filled can when required by a liquidheight measurement detection beam; (2) a body which is dimensionally thesame as the actual container in use and which comprises enough weightfor stable travel on a conveyor; and (3) a relieved can bottom surfacewhich provides additional stability for travel on a conveyor. Thesimulated cans may be provided in any fixed size, such as eight, twelve,and sixteen ounce models.

In addition to fill height quality assurance, quality inspectioncomprises missing cap, high or cocked cap, missing lid, and bulgedcontainer testing.

The aforementioned static simulated can, however, presents problems ofits own including customer errors in incorrectly permanently affixingthe lid to the remained thereof and the inability to adjust the sizethereof at later points in time to accommodate a different fill level.

BRIEF SUMMARY AND OBJECTS OF THE INVENTION

In brief summary, this novel invention alleviates problems related toquickly and accurately setting fill levels and/or other parameters forcontainers processed by filling and sealing (closure applying) equipmentusing a dynamic, adjustable simulated test container. This invention,therefore, provides novel, adjustable fill height test devices which aremanually adjustable and used to calibrate run parameters the first timea line is set-up and then stored reuse each time the line is reset andeach time a control test is necessary or advisable. In addition, whenadjusted to be a specific, desired standard, any dynamic, adjustablesimulated test container according to the present invention may bedimensionally used as a basis for the manufacture of additionaldisposable test containers for use as non-retrievable test containers incertain types of filling and sealing systems. In its presently preferredform, the invention comprises three major parts, i.e. a base support, anadjustable fill height gauge block, and an adjustable mounting stem orshaft which can be used to set container height. These parts combine toprovide two manually adjustable equipment detectable height settings forautomatically filling a continuous line of containers with liquid, foodor the like.

It is common practice in the industry to measure fill level usingscintillation tubes, which generate low energy gamma radiation toproduce a fill measurement or reading for each successive container in aline of containers being filled with a desired substance. The presentinvention simulates not only a container, but a product-air interfacenear the top of the simulated container closely enough that no change insensitivity of the height measurement gamma radiation sensor isrequired. The fill height feature of the present invention is manuallyadjustable and may securely but releasibly be affixed in a desiredposition at a height which determines the test level. The presentinvention also comprises a container height adjustment feature.

In practice, two or three preset adjustable simulated containersaccording to the present invention are typically used. One device is setto measure the maximum product height reject level, a level at which onehundred percent of containers filled to that level are rejected. Asecond device is set to measure a product height which is greater thanthe maximum product height reject level by a distance equal to thequality inspection system's minimum detection resolution, a level atwhich one hundred percent of the containers filled to that level pass.Optionally, a third device is set to measure a product height betweenthe first two devices, a level at which some containers pass and therest are rejected. Different colored test containers or parts thereofmay be provided to allow devices set for different measurementparameters to be visually differentiated and selected by the user. Also,where the adjustable test containers replicate long necked bottles theymay each be crowned with a bottle cap for testing bottle cappinginspection parameters.

It is a paramount object of the present invention to provide novelstructure and methods which overcome or alleviate the aforestatedproblems of the prior art and by which fill levels and/or otherparameters for container filling and sealing (closure applying)equipment is established with accuracy and precision.

It is also a primary object to provide manually adjustable fill heighttest devices in the form of simulated containers by which filling andsealing equipment is calibrated to cause each in a line of containers tobe correctly filled.

It is a key object to provide one or more fill height test devices eachof which is manually adjustable and which retains the adjustment againstinadvertent change accommodating periodic reuse.

It is a further key object to provide a fill height test device which isdurable and has a long life expectancy.

It is a fundamental object to provide one or more manually adjustablesimulated containers, each of which is used to calibrate containerheights and fluid levels for container filling and sealing equipment.

It is a elemental object to provide an adjustable simulated containerwhich comprises a base suitable for stable travel on a conveyor or thelike.

It is a main object to provide a manually adjustable multiple partdevice for calibration of container filling and sealing equipment.

It is a chief object to provide parts for manually set and adjustablecalibrating devices in an assortment of colors such that devices ofdifferent manual settings are visually distinguishable any one fromanother.

It is a significant object to provide a selectively set, manuallyadjustable container simulator the setting of which is detectable by aproduct fill height detector and which requires no change in sensitivityof the detector when the simulator is used as a standard or control.

It is an important object to provide an adjustable fill height device inthe form of a simulated narrow neck bottle which comprises a bottle capfor filling and sealing calibrations of equipment which inspects bottlesupon which bottle caps have been superimposed.

It is an further important object to provide an adjustable fill heightsimulated container which does not slosh due to conveyor movement andvibration.

These and other objects and features of the present invention will beapparent from the detailed description taken with reference toaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a can simulating fill height test devicefashioned according to the principles of the present invention;

FIG. 2 is an exploded isometric view of the fill height test device forcans seen in FIG. 1, with an optional cap added;

FIG. 2A is a cross-section taken along lines 2A--2A of FIG. 2;

FIG. 3 is an isometric view of a bottle simulating fill height testdevice fashioned according to the principles of the present invention;and

FIG. 4 is an exploded isometric view of the fill height test deviceshown in FIG. 3.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Reference is now made to the embodiments illustrated in FIGS. 1-4wherein like numerals are used to designate like parts throughout.

The first presently preferred embodiment of the invention comprises anassembled, can simulating, free-standing, fill height test device,generally designated 10 and best shown in FIG. 1. An exploded view ofthe same device is shown in FIG. 2, where an optional cap 90 is alsodepicted. As can be clearly seen in FIG. 2, parts for test device 10comprise base support member, generally designated 30, releasiblefasteners in the form of four retention set screws 40, fill height gaugeblock, generally designated 20 and a shaft, mast or column member,generally designated 80. As mentioned, the cap 90, shown in FIG. 2, isoptional.

Base support member 30 is preferably made of high impact injectionmolded synthetic resinous material, which causes the test device to befree-standing and comprises enough weight to provide stability for theentire simulated container 10 during use when placed upon a movingconveyor or the like. While the form of base support 30 is shown to becylindrical in shape, the invention embraces all shapes utilized asfillable containers. The support member 30 comprises an exteriorcylindrical surface 31 and spaced inside arcuate surfaces 94. The wallbetween surface 31 and surfaces 94 is, with two exceptions mentionedbelow, illustrated as being of uniform thickness.

Opposed threaded bores 42, only one of which is not shown, are providedin the wall forming member 30 and each extends from surface 31 to one ofthe surfaces 94. Each bore 42 receives a set screw 40, as will bediscussed in detail later. The hollow center defined by surfaces 94comprises a smooth blind bore 34 which extends vertically downwardlyalong the longitudinal axis of the member 30 from top surface 38 to apoint a small distance above contoured base support bottom surface 32sufficient to maintain structural integrity. The circular nature of bore34 is interrupted by two oppositely positioned internal grooves 36 whichextend radially into the wall of member 30. Thus, opposed keyways at 36are provided. Base support contoured bottom surface 32 preferablycomprises a relieved configuration which replicates the bottom surfaceof a beverage can or the like for by which the device 10 is caused to befree-standing upon a desired surface and will stably travel on aconveyor or the like surface in its free-standing condition.

Shaft member 80 is preferably made from high impact injection moldedsynthetic resinous material and comprises a central vertical shaft 81comprising cylindrical surface segments 83. Two opposed, radiallyprotruding longitudinally directed keys 86 interrupt the surfaces 83.The keys 86 are sized, shaped and located to accommodate lineardisplacement along keyways 36 of member 30 as the shaft 81 is linearlyinserted into bore 34. When the shaft 81 is so inserted into bore 34 thefit is preferably snug but not tight.

The shaft member 80 comprises a flat transverse bottom surface 82 and aflat transverse top surface 88. Each key 86 is illustrated as extendingfrom the top surface 88 at points 84 to sites 76 located above thebottom surface 82.

Two oppositely directed identical flats 60, only one of which is shown,are interposed between surface 83 on opposite sides of the shaft 81, andare provided to contiguously receive retention set screws 40 in abuttingrelation. Flats 60 are formed parallel to the planes of protruding keys86 and normal to the axis of each set screw 40, when assembled. Eachsurface 60 is so dimensional that any damage incurred by any set screw40 will not adversely affect travel of shaft 80 in bore 34 keyways 94.Each flat 60 extends to bottom surface 82, but does not extend the fulllength of shaft 80 to top surface 88. Instead each flat 60 begins apredetermined distance below top surface 88 at site 96, such that thecylindrical nature of the top part of shaft member 80 is maintained,exclusive of keys 86. Thus, each flat 60 in shaft 80 begins at a site96, which is sufficiently above the highest possible position of atightened retention screw 40 that raising and scoring material at thetop of flat 60 which would or might adversely affect travel of shaft 80in bore 34 is avoided.

Fill height gauge block 20 is annular-shaped and comprises a solid walldefining exterior arcuate surface 21 and interior arcuate surfaces 74.The diameter of surface 21 is illustrated as being the same as thediameter of surface 31 and the diameter of surfaces 94 the same assurfaces 74. Block 20 also comprises a flat transverse bottom surface 71and a flat transverse top surface 70. Surface 70 is the surfaceinterpreted by product height sensors of a quality inspection system asif surface 70 where the top surface of a product dispensed into acontainer. Thus, annulus 20 at surface 70 simulates a fill level ofproduct in a container. Block 20 is preferably formed of high impactsynthetic injection molded resinous material, which has proved to haveboth the rugged physical and air-to-surface interface characteristics toaccommodate repeated use without undue wear or damage, without requiringrecalibrating or other alteration of the sensitivity of the productlevel sensor of the associated quality inspection system. Fill heightgauge block 20 comprises two opposing threaded bores 22 disposed in thewall comprising block 20 and extending between surfaces 21 and 70, Eachbore 22 receives one of the retention screws 40. Fill height gauge block20 also comprises axial bore 24 which is interrupted by two opposedinternal longitudinally directed grooves 26. The diameter of bore 24 isillustrated as being the same as the diameter of bore 94 and slots 26are sized, shaped and located as are slots 36. Note that a planecontaining slots 26 and 36 is disposed normal to the axis of eachthreaded bore 22 and 42. Thus, entry of each retention screw 40 throughits associated threaded 22, 42 directly opposes an associated flat 60 ofthe shaft member 80.

Assembling of test device 10 involves telescopic, nonrotatableinterrelating parts and comprises linear insertion of shaft member 80through fill height gauge block 20 and into the base member 30 such thatshaft member 80 is in a vertically erect position, surfaces 88 and 70are coplanar and keys 86 are aligned with keyways 26 to prevent relativerotation of block 20 and shaft 80. Two set screws 40 are inserted intothreaded bores 22 and tightened against the associated flats 60 whilethe coplanar relationship between surfaces 88 and 70 is retained. Bottom82 of shaft member 80 is linearly inserted into base support 30 bore 34with keys 86 and keyways 36 aligned to prevent relative rotation untilthe height represented by the distance from base support bottom 32 tocoplanar surfaces 88 and 70 is the desired fill height. At this point, aretention screw 40 is inserted into each threaded bore 42 and tightenedagainst the associated flat 60. An uncapped simulated fill heightcalibrating can is thus ready for use.

If it is desired to simulate a can comprising a lid, for reasonscomprising triggering requirements of product level measuring equipment,cap 90 is used. Cap 90 comprises a top layer of uniform thicknesscomprising top surface 92 and bottom surface 91 and an annular,downwardly extending flange 98, ending in edge 99 which defines aninternal recess between flange 98 and surface 91, which is required bysome measurement equipment. The height of flange 98 of cap 90 is sizedto provide a recess adjacent bottom surface 91 which simulates thatfound in filled containers.

Another presently preferred embodiment of the invention is illustratedin FIGS. 3 and 4 and comprises a bottle simulating, free-standing, fillheight test device 560. As can be clearly seen in FIG. 4, parts for testdevice 50 comprise the above-described base support member 30, fourreleasible fasteners in the form of the described retention set screws40, the described fill height gauge block 20, shaft, mast or columnmember 80', and bottle cap 90'. Where parts of device 50 are illustratedas being the same as those which comprise device 10 like numbers havebeen used and no further description of these parts is necessary.

Shaft member 80' comprises a vertical shaft 81' comprising a generalcylindrical shape with two producing radially-directed keys 86'(external flanges) which, together, comprise a horizontal silhouettewhich insertably fits and slides into bores 24 and 34. Keys 86' eachextend from a top site 84', which is sufficiently below top surface 88'of the shaft member 80' to accommodate placement of bottle cap 90' overthe top end of shaft member 80', to a lower site 76'. Shaft top surface88' is illustrated as being flat and transverse to the axis of member80'. The edges of top 88' are preferably rounded.

Two opposing flats 60' (one is not shown) are provided to engage thedistal edge of retention set screws 40. Flats 60' are parallel to theplane of protruding keys 86', but are 90 degrees from the keys 86'. Thesurface are of each flat 60' of shaft member 80' is large enough so thatscoring and other damage caused by tightening retention screws 40 willnot adversely affect travel of shaft 80' in bore 94. Each flat 60' doesnot run the full length of shaft 80', but begins at site 96', located adistance below top 88', such that op 88' retains a circular form. Inother words, site 96 of flat 60' begins at a point sufficiently abovethe highest possible position of a tightened retention screw 40 to avoidscoring and other damage at the top of flat 60' which will adverselyaffect travel of shaft 80' in bore 34.

As stated before, the top surface 70 of fill height gauge block 20 isthe critical surface interpreted by product height sensors of a qualityinspection system as if it were the top surface of product placed in acontainer.

Assembling of test device 50 involves telescopically and nonrotatablyinterrelating parts and begins with vertically erect, linear insertionof shaft member 80' into the bore 34 of base support member 30 with keys86' aligned with keyways 36 to prevent relative rotation until topsurface 88' is located at the desired bottle height. Two set screws 40are inserted into threaded bores 42 and tightened against associatedflats 60' to retain shaft member 80' at the desired height. Fill heightgauge block 20 is linearly inserted at bore 24 over shaft member 80'with keys 86' and keyways 26 aligned to prevent rotation, and lowereduntil the height represented by the distance from base support bottom 32to planar surface 70 is the desired fill height to be simulated bydevice 50. At this point two retention screws 40 are inserted intothreaded bores 22 and tightened against associated flats 60'. Theuncapped fill height measurement device 50 is thus ready for use.

If a bottle cap is desired, for reasons comprising inspecting formissing or high/cocked caps, cap 90 is compressibly or adhesivelyapplied to the top region of shaft member 80'.

In use, at least two models of each free-standing device 10 and 50 areemployed in fill level calibration of automated contained filling,closure applying and sealing equipment, shown diagrammatically at 8 inFIGS. 1 and 3. A first model comprises a NO GO product height levelwherein the distance between base support bottom 32 and planar surface70 is set to the maximum rejectable product height. At this maximumrejectable level one hundred percent of the tests in said equipmentusing the present test devices results in rejection. A second model,usually made from parts of a different color, is adjusted to be a GO(i.e. one hundred percent of the tests on the second model result in apass). The GO height is located above the NO GO a distance whichcomprises the detection resolution of the quality inspection system. Inpractice, an iterative process of repeated testing and height adjustmentis required to finely tune each model to meet the one hundred percentGO/NO GO criteria. Optionally, a third model is assembled whichcomprises a base support bottom 32 to planar surface distance which isintermediate between the GO and NO GO heights providing a device whichpasses a portion of the time and is rejected the rest of the time.

The invention may be embodied in other specific forms without departingfrom the spirit or essential characteristics thereof. The presentembodiments are therefore to be considered in all respects asillustrative and not restrictive, the scope of the invention beingindicated by the appended claims rather than by the foregoingdescription, and all changes which come within the meaning and range ofequivalence of the claims are therefore intended to be embraced therein.

What is claimed and desired to be secured by Letters Patent is:
 1. Acombination comprising a container filling and closure applyingapparatus and an adjustable fill height test device which simulates acontainer filled with material to a predetermined level by which thecontainer filling and closure applying apparatus is calibrated, theadjustable fill height test device comprising:a base for stablysupporting the test device, said base comprising means for contiguouslyengaging a supporting surface upon which the test device rests; a columnwhich is supported and held in an erect vertically-extending conditionby the base; means for simulating a fill level, the fill levelsimulating means being supported by the column; means by which theelevation of the fill level simulating means are adjusted and secured inrespect to the base to a location above said base which accuratelysimulates the desired fill level of a container.
 2. The combinationaccording to claim 1 further comprising means by which the base and thecolumn are telescopically interrelated.
 3. The combination according toclaim 2 wherein the means which telescopically interrelate the base andthe mast prevent relative rotation of the column and the base.
 4. Thecombination according to claim 2 wherein the means which telescopicallyinterrelate the base and the mast further comprise releasible fasteningmeans interposed between and which releasibly securely join the base andthe column whereby the relative positions of the base and the column areselectively releasibly set by a user.
 5. The combination according toclaim 4 wherein the releasible fastening means comprise at least one setscrew.
 6. The combination according to claim 1 further comprising meansby which the column and the fill level simulating mean aretelescopically interrelated.
 7. The combination according to claim 6wherein the telescopically interrelating means prevent relative rotationof the column and the fill level simulating means.
 8. The combinationaccording to claim 6 further comprising means interposed between thecolumn and the fill level simulating means by which the relativepositions of the column and the fill level simulating means areselectively releasibly set by a user.
 9. The combination according toclaim 8 wherein the releasible fastening means comprise at least one setscrew.
 10. The combination according to claim 1 further comprising meansfor simulating a container closure disposed at the top of the testdevice which simulate a top closure of the container.
 11. Thecombination according to claim 10 wherein the container closuresimulating means comprise means for simulating a can lid.
 12. Thecombination according to claim 10 wherein the container closuresimulating means comprise means for simulating a bottle cap.
 13. Acombination comprising container filling and closure applying equipmentand an adjustable fill height test device which simulates a containerfilled with material to a predetermined level for calibrating thecontainer filling and closure applying equipment, said adjustable fillheight test device comprising:a base for structurally supporting thedevice by engaging a supporting surface, a mast, means simulating aheight of the container, means for joining the base and the containerheight simulating means, and means for preventing relative rotation butaccommodating relative reciprocation of the container height simulatingmeans and the base; releasible fastening means interposed between thebase and the container height simulating means by which the relativepositions of the mast and the container height simulating means arereleasibly set; a fill height gauge for simulating a desired fill heightof the container, means for engaging the mast and means for preventingrelative rotation of the fill height gauge relative to the mast wherebythe relative positions of the fill height gauge and the mast may bevaried only rectilinearly; means for releasibly fastening together thefill height gauge and the mast whereby the relative positions of thefill height gauge and the mast are releasibly set to simulate a desiredcontainer fill level.
 14. The combination according to claim 13 whereinthe mast, the fill height gauge, and the base each comprise color codedsynthetic resinous material.
 15. The combination according to claim 13wherein the releasible fastening means comprise a plurality of screws,each carried in a threaded bore disposed in the base and which are eachcaused to bear against a surface of the mast when appropriately rotatedin the threaded bores.
 16. The combination according to claim 13 whereinthe means for structurally defining the base comprises a contouredbottom surface which simulates the bottom surface of the container. 17.The combination according to claim 13 wherein the base, the mast, andthe fill height gauge each comprise a separately injection molded partof synthetic resinous material.
 18. A method of calibrating a containerfilling and closure applying apparatus comprising the steps of:a.providing at least one fill height simulating device; b. physicallyadjusting one solid fill height simulating component of the fill heightsimulating device in respect to a second solid component to change theelevation of the simulated fill height level of the fill heightsimulating device to set a desired fill height; c. processing the fillheight simulating device through the container filling and closureapplying apparatus whereby the simulated level is measured by thecontainer filling and closure applying apparatus; d. calibrating thecontainer filling and closure applying apparatus from measurements madein the processing step.
 19. A method of testing filling level testlimits of a container filling and closure applying apparatus comprisingthe steps of:a. providing at least one fill height simulating device; b.adjusting one solid fill height simulating component of the device tochange the elevation of the simulated fill height level of the fillheight simulating device to set a desired test limit; c. processing thefill height simulating device through the container filling and closureapplying apparatus whereby the simulated material level is measured bythe container filling and closure applying apparatus; d. failing thetest if the measurement made by the container filling and closureapplying apparatus is inconsistent with the adjusted elevation of thesimulated fill height level.